Hybrid composite tailgate

ABSTRACT

The invention relates to a hybrid tailgate for a vehicle, comprising a thermoplastic inner structure forming the carrier frame of the tailgate, and at least one composite reinforcement part to reinforce the carrier frame, wherein the composite reinforcement part is connected to the thermoplastic inner structure at a first surface, wherein the composite reinforcement part forms a continuous load path in the inner structure enclosing a tailgate window opening for a window glazing part of the tailgate. Furthermore, the invention relates to a vehicle comprising such a hybrid tailgate. Moreover, the invention relates to a method of manufacturing such a hybrid tailgate, the method comprising forming a composite laminate part into an insert; placing the insert in an injection molding tool; and over-molding the insert with polymer resin.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a hybrid tailgate or rear door for avehicle, in particular a motorized vehicle such as a car, comprising athermoplastic inner structure and composite reinforcements. Theinvention further relates to a vehicle comprising such a hybridtailgate. Moreover, the invention relates to a method for manufacturingsuch a hybrid tailgate.

Description of the Related Art

Weight reduction is key to automotive due to stringent worldwide carbondioxide emission regulations. As a result, most lightweight solutionstoday use optimized aluminum or high strength steel designs for tailgateapplications. Weight reduction is sought by using aluminum to maintainthe required mechanical properties. Using aluminum is costly, due tomaterial costs and the need of parts that are individually clad (usuallymade of thermoplastic polyolefins (TPO)) to meet aesthetical interiorrequirements.

To further reduce the weight, and to additionally reduce costs, plastictailgates were sought after. Initially, plastic tailgates were developedfrom thermoset SMC-like materials. Sheet molding composite (SMC) is aready to mold glass-fiber reinforced, thermoset, polyester material.Later on, thermoplastic parts were made of Long fiber reinforced PP(PP-LGF) that partially integrate the aesthetical TPO panels. However,these parts mostly contain metal inserts that are either over-molded,bolted to or glued to the inner structure. The metal inserts are neededto meet mechanical and thermal expansion requirements.

Current ongoing investigations are directed to replacement of the metalinserts by continuous fiber reinforced (FR) inserts. These FR insertscan be of the woven (bended fibers) or the laminate type (straightfibers).

Recently, thermoplastic composites have been used as alternativematerials for tailgate inner structures. American patent publicationU.S. Pat. No. 8,550,536 describes such a tailgate using fiber-reinforcedthermoplastic plastic material. Often, metal hybrid structures combininga metal insert with PP-LGF are used.

Full thermoplastic tailgate inner structures combining TPO withcomposite material offer potential for further decrease in weight(weight out), part integration and reduction in costs (cost out).

BRIEF SUMMARY OF THE INVENTION

According to the invention, there is provided a hybrid tailgate for avehicle, comprising a thermoplastic inner structure forming the carrierframe of the tailgate, and at least one composite reinforcement part toreinforce the carrier frame, wherein the composite reinforcement part isconnected to the thermoplastic inner structure at a first surface,wherein the composite reinforcement part forms a continuous load path inthe inner structure enclosing a tailgate window opening for a windowglazing part of the tailgate.

The inner structure comprises a tailgate window opening in which awindow glazing part of the tailgate may be placed. The reinforcementpart forms a continuous load path in the inner structure enclosing orsurrounding the tailgate window opening.

The carrier frame may comprise a top beam, two D-pillars extending fromeach end of the top beam, and a lower portion extending between the twoD-pillars at a distance different from zero from the top beam. The topbeam, D-pillars and the lower portion enclose the tailgate windowopening for a window glazing part of the tailgate.

The composite reinforcement part is connected to a first surface of theinner structure, either by injection molding, overmolding, or adhesionby welding or gluing.

Preferably, the composite reinforcement part is connected to and formsan integral unit with the thermoplastic inner structure at the firstsurface, wherein the composite reinforcement part comprises a ribbingstructure extending from the first surface, which ribbing structureforms a continuous load path in the inner structure surrounding thetailgate window opening.

The ribbing structure is part of the inner structure to reinforce thecarrier frame and extends from a first surface of the inner structure.The ribbing structure can comprise ribs directed parallel, perpendicularand/or diagonally with respect to the top beam of the carrier frame.

The inner structure can have a thickness ranging from 0.9 mm to 5.0 mm,preferably 1.0 to 4.0 mm, more preferably 1.5 to 4.0 mm. The thicknessmay vary over the area covered by the inner structure. The ribbing orribbing structure may have a thickness ranging from 0.6 to 5.0 mm,preferably from 1.0 to 4.0 mm.

According to an embodiment, the reinforcement part comprises a base andat least one upstanding reinforcement wall extending from a secondsurface of the base of the reinforcement part, wherein the upstandingwall forms a ribbing along the base. The reinforcement part is thusconnected to the inner structure at the first surface. The upstandingwall may be a wall extending along a first edge of the base and/or asecond edge of the base. Further, the upstanding wall may extend betweenthe first and second edges at an angle ranging from −90° to +90°,preferably −45° to +45°. Preferably, the upstanding walls along the baseand/or extending between the first and second edges forms part of theribbing structure.

According to another embodiment, wherein the reinforcement part furthercomprises a composite material laminate, comprising at least one layerof a composite tape having a thermoplastic matrix material withcontinuous reinforcing fibers embedded in the matrix material. In thisembodiment, the at least one composite reinforcement part comprises acomposite material tape made of comprising a layer of matrix materialwith continuous reinforcing fibers embedded in the matrix material. Thematrix material is preferred to be a thermoplastic material, such as apolyolefin. The continuous reinforcing fibers may be directed in thelongitudinal direction of the tape. The term ‘continuous fiber’ mayrefer to fibers having the same length as the tape, i.e. the fiberstretches the length of the tape.

Preferably, the laminate is made of two or more layers of the compositetape. The continuous fibers in each layer may be oriented in a differentdirection with respect to a longitudinal direction of the tape. Theorientation of the fibers in one layer with respect to the fibers inanother layer may range from −90° to +90°. A preferred angle between thelongitudinal direction of the continuous fibers of a first layer and thelongitudinal direction of the continuous fibers of a second layer rangesfrom −45° to +45°. The thickness of the laminate can range from 0.1 mmto 6.0 mm. The thickness of one layer may vary from 0.1 mm to 0.3 mm.Preferably, a multiple layer laminate is used, having a thicknessbetween 1.5 and 4.5 mm, more preferably between 2.0 and 4.0 mm. Thethickness of the laminate may vary over its width and/or longitudinaldirections, to locally increase reinforcement. This may be advantageousto an improved stress distribution at for instance the hinge connectionportion, the gas strut connection portion, and/or the lock receivingportion which are typically the high load areas of the tailgate.

The laminate may be further overmolded with thermoplastic material atleast compatible with the thermoplastic material of the inner structure,preferably similar. The thickness of the overmolded layer may range from1.0 to 2.0 mm, preferably 1.5 mm.

The composite material laminate may form at least a portion of the baseof the reinforcement part. The upstanding wall forming the ribbing mayextend from the base formed by the laminate. Preferably, the compositematerial laminate is provided at one or more of a D-pillar, a top beamand a lower portion, extending at least over the hinge connectionportion, the gas strut connection portion, and/or the lock receivingportion. Where the composite material laminate is not applied or cannotbe applied, the ribbing or ribbing structure is provided, wherein theribbing or ribbing structure at least partly overlaps with the compositematerial laminate to form the continuous load path in the innerstructure. The ribbing or ribbing structure may also be applied for easeof manufacturing, for instance at corner regions, e.g. at the transitionfrom the top beam to the D-pillar.

Depending on the design of the inner structure, applying just theribbing structure as the reinforcing part may not be sufficient foroptimal reinforcement of the inner structure, especially at theD-pillars. To optimize the reinforcement of the inner structure, a firststep could be to provide the composite material laminate at theD-pillars, in addition to the ribbing structure. Additionally, thecomposite material laminate can be provided at the top beam. Whenfurther reinforcement is needed, the composite material laminate mayalso be added to the lower section (below back lite), furthermorecovering complete inner surface area. To close the continuous load path,the ribbing or ribbing structure at least partially overlaps with thecomposite material laminate. Preferably, ribbing is present in allembodiments, to form a closed loading path from top beam to lock area.It is observed that the more area of the inner structure is reinforcedwith the composite material laminate, the more weight reduction withrespect to traditionally reinforced inner structures can be achieved.

The hybrid tailgate is preferred to be free of metal reinforcementparts, or any metal inserts, except the lock of the rear door, i.e. thelock of the rear door or tailgate may be a metal lock, and possibly thehinges that may comprise one or more metal parts.

The thermoplastic inner structure may comprise, or consist of, acombination of a polypropylene (PP) reinforced with long fibers, forinstance 30 to 60 wt. %, preferably 40 wt. % long glass fibers (PP-LGF),e.g. STAMAX® manufactured by SABIC. Using PP-LGF in combination withcomposite laminate inserts, either a woven or a unidirectional laminatewith a certain ply stacking comprising of a certain shape, andconnecting the main loading areas (hinge, gas strut and lock), anequally (mechanically) performing tailgate can be achieved withsignificant weight savings compared to tailgates with a traditionalsteel or aluminum inner structure or carrier frame.

The composite tape may comprise a polypropylene reinforced withcontinuous fibers, e.g. continuous glass fibers. The composite laminatemay comprise two or more unidirectional tapes, which are stacked on topof each other under certain stacking angles or ply angles. Furthermore,the reinforced tape can comprise 30 to 60 vol. %, preferably 45% vol.continuous glass fibers. The laminate can be pre-shaped asthree-dimensional laminate inserts. These laminate inserts can beinserted in an injection molding cavity to be overmolded with athermoplastic material, for example a polyolefin, preferably a similarthermoplastic material as the matrix material of the composite materialto enhance bonding between the base and the overmolded material.Alternatively, the laminate inserts can be connected by other methodssuch as gluing, bolting, clipping, etc. but this will negatively affectthe mechanical performance and total costs.

The laminate may comprise a tape of unidirectional continuous fibers ina matrix material. Woven fibers, e.g. a textile from reinforcing fibers,can be used as well. However, CF-composite laminates offer superiorstiffness and strength versus woven fibers composites and long,non-continuous, fiber filled materials, due to the continuous length ofthe fibers, i.e. the length of the fibers coincides with the length ofthe tape layer.

The tailgate may further be provided with a hinge connection portion, agas strut connection portion, and/or a lock receiving portion, wherein alock can be received for connection with the tailgate. Further, thecontinuous load path, i.e. the reinforcement part, may extend from afirst side of a lock receiving portion provided in the tailgate, to asecond side of the lock receiving portion, where the lock receivingportion closes the loop or path. The hinge connection portion may beused to connect the tailgate via hinges to the vehicle and may belocated at an upper side of the tailgate window opening, near an upperside of the inner structure. The gas strut connection portion may beused to connect the gas struts to the tailgate and may be located ateither end sides of the tailgate window opening. The lock receivingportion may be located at a lower side of the tailgate window opening,opposite the hinge connection portion, preferably at a location betweenthe lower side of the tailgate window opening and a lower side of theinner structure.

The reinforcement part forms a continuous load path in the innerstructure, for example from the hinge connection portion via the gasstrut connection portion to the lock receiving portion. Optimal use ofthe reinforcement parts, i.e. locating them at areas of high loading,may reduce weight significantly. To form the continuous load path, mainareas of high loading need to be connected by means of the reinforcementpart. Such areas of high loading are the area between the hingeconnection portions, the area between the hinge connection portions andthe gas strut connection portions, and the area extending between thegas strut connection portions and the lock receiving portion.

As such, the reinforcement part may comprise a top reinforcement partfor strengthening a top part or top beam of the inner structure, aD-pillar reinforcement part for strengthening the D-pillars of the innerstructure and/or a further reinforcement part extending between theD-pillar reinforcement part to the lock receiving portion. When forminga continuous load path, the reinforcement part may be a continuousreinforcement part where the top reinforcement part is connected to aD-pillar reinforcement part at both ends, and where each D-pillarreinforcement part is connected to the further reinforcement part thatextends towards the lock receiving portion of the inner structure of thetailgate.

The tailgate and its inner structure may have different shapes. Forinstance, where an upper portion comprising the tailgate opening, andthe lower portion are in the same plane, i.e. where the normaldirections of these respective portions are parallel, or where the upperportion and the lower portion are at an angle different from 0 or 180degrees, i.e. where the normal directions of these respective portionsare at an angle different from 0 or 180 degrees, thus forming an anglein the inner structure.

EXAMPLE 1

This first example, shown in FIG. 1, comprises a first tailgate 1 withan inner structure 2 fully made of PP-LGF, i.e. polypropylene matrixwith long glass fibers reinforcement, with 40 weight. % of long glassfibers in the thermoplastic matrix. This first tailgate design is about18% lighter compared to an aluminum design. Because of the relativelythick ribbing, this design is limited to the use for non-aestheticalparts. However, with increasing cross sectional area at the location ofthe D-pillar, thinner ribbing can be applied, making the design moresuitable for aesthetic purposes.

The inner structure 2 is provided with a tailgate window opening 6 inwhich a window glazing part of the tailgate can be placed. This windowglazing part may be an integral glazing part made of a transparentthermoplastic material, or a traditional glass window that is placed inthe window opening at a later stage of the vehicle assembly. Thereinforcement part 9 forms a continuous load path in the inner structure2 enclosing the tailgate window opening 6.

The top reinforcement part 4 between the hinge connection portions 8 andthe D-pillar reinforcement part 13 between the hinge connection portion8 and the gas strut connection portion 7 comprises a ribbing structure 3that may have a known ribbing pattern, i.e. a common reinforcementpattern. The further reinforcement part 12 between the gas strutconnection portions 7 and the lock receiving portion 5 may be realizedwith a further ribbing structure 14 that may have a non-common ribbingpattern and possibly a partial aesthetical surface. The ribbing patternmay include parallel opposite ribs with ribbing extending between theparallel ribs, where the ribbing runs diagonally, i.e. at an angledifferent from 0 or 180 degrees, with respect to the parallel ribs. Theribbing structures 3, 14 are integrally injection molded with the innerstructure.

When the further reinforcement part is provided with the partiallyaesthetical surface, it has the advantage that no extra cladding, i.e.covering, is needed for finishing the tailgate. However, such anaesthetical surface would imply that the ribs or upstanding walls willbe limited in thickness to avoid sink marks in the surface, or thatthere would be no upstanding wall or ribbing present at the location ofthe aesthetical surface.

EXAMPLE 2

This second example, as shown in FIG. 2, comprises a second tailgate 1′with an inner structure 2′ made of PP-LGF reinforced with CF-laminatereinforcements 10′, 11′, 12′, i.e. an inner structure of PP-LGF withreinforcement parts comprising continuous fiber laminate material. Theshape of the inserts is relatively flat to facilitate production andreduce costs, as no or at least only little preforming of the inserts isneeded. The laminate parts used for the inserts may vary in thickness.For this second example, the optimal thickness are found to be 10-14layers for the top reinforcement part 10′, located between the hingeconnection portions 8′ (area 1), for the D-pillar reinforcement part 11′between the hinge connection portions 8′ and each of the gas strutconnection portions 7′, 8-18 layers (area 2), and for each of thefurther reinforcement parts 12′ between the gas strut connectionportions 7′ and the lock receiving portion 5′ (area 3) 6-8 layers, whereall layers have ply angles of 0°, 45°, or −45°.

The top reinforcement part 10′, the D-pillar reinforcements parts 11′and the further reinforcement parts 12′ between the gas strut connectionportions 7′ and the lock receiving portion 5′, forms a reinforcementpart 9′ constituting a continuous loading path. It is noted that in thisexample the CF-laminate forms the base of the reinforcement part, i.e.the ribbing is bonded to the base by over-molding the laminate with thePP-LGF material and forming a ribbing structure with upstanding walls,as described below.

This second example resulted in a weight reduction of about 35% comparedto an aluminum tailgate design. Optimization of ply angles has shownthat the optimal angles are close to the 0, 45, −45, 0° design. Forexample, the continuous fibers of a second tape layer may have an angleof 45° in a clockwise or counterclockwise direction with the continuousfibers of the first tape layer. This design has the advantage ofimproved long term loading or creep performance and a further weightreduction over the first design in Example 1.

EXAMPLE 3

This third example, as shown in FIG. 3, comprises a third tailgate 1″with an inner structure 2″ made of PP-LGF reinforce with pre-formedCF-laminate reinforcement parts 10″, 11″, 12″. The CF-laminatereinforcement parts have been pre-formed to a certain three-dimensionalshape, see FIG. 5. This CF-laminate insert is a 3D shaped insert in aninjection molding tool. The pre-formed CF-laminate part is part of thereinforcement part. The ribbing, is bonded to the base by over-moldingthe shaped laminate with the PP-LGF material, for instance byovermolding the ribbing structure into a channel shaped portion of the3D insert.

The 3D laminate pre-form or insert provides additional weight reduction,but adds complexity to the manufacturing process and thereby adds costs.This third example is believed to achieve a weight reduction up to about42% compared to a regular aluminum design of the tailgate.

EXAMPLE 4

In FIGS. 2 and 3, the continuous fiber laminates are placed in criticalload bearing locations. Alternatively, or additionally, the CF-laminatecan cover a larger surface area 15* in the lower portion of the innerstructure, as shown in FIG. 4. The laminate is formed as relatively bigsections of UD-tape-like plates. The laminate reinforcement area 15* inFIG. 4 leaves space for the locking receiving portion 5* and isconnected with the D-pillar reinforcement parts 11* to form a continuousload path with the top reinforcement part 10*, enclosing the windowreceiving opening 6* in the tailgate inner structure 2*.

FIG. 5 shows several shapes of the ribbing structure 22 and anyassociated laminate insert 23. The laminate insert 23 may be athree-dimensional shaped form having one or more channel shaped portions24, that may be overmolded with thermoplastic resin, see column B andblock D1 of FIG. 5. The laminate insert may alternatively be a flatinsert that is located at one or more sides of the ribbing 22, seecolumn C and blocks D2 and D3 of FIG. 5. Column A of FIG. 5 showsseveral forms of the ribbing structure 22 without a laminate insert.

FIG. 6 shows that the tailgates according to Examples 1-4, as shown inFIGS. 1-4, meet the requirements concerning the torsion strength,C-bending strength, L-bending strength, lateral bending and the Eigenfrequency. The present requirements (25) are set at 100%, and then therelative value of each property is given for the PP-LGF only innerstructure (26), see example 1; the inner structure composed of PP-LGFwith flat laminates (27), see example 2; the inner structure composed ofPP-LGF with 3D pre-formed laminates (28), see example 3; and the innerstructure composed of PP-LGF with laminate plates (29), see example 4.

The weight distribution between the PP-LGF and CF-laminate used in thedifferent designs of the structural inner part is shown in FIG. 7Error!Reference source not found. From this graph it can be observed that thehigher the contribution of the CF-laminate, the more weight-reductionfor the inner structure, and thereby the hybrid tailgate, is achieved.The inner structure composed of PP-LGF with flat laminates (bar 19,Example 2) is approximately 73% of the weight of the inner structurefully composed of PP-LGF with no laminate reinforcements (bar 18,Example 1). Using 3D pre-formed laminate inserts (bar 20, Example 3)compared to flat laminate inserts (bar 19) reduces the weight to about64% of the weight of the inner structure fully composed of PP-LGF withno laminate reinforcements (bar 18, Example 1). However, this willincrease the costs, as the amount of laminate material used hasincreased, and there is a need for more complex tooling, or anadditional process step of preforming the insert into the desired shape.Similar reasoning can be applied to the laminate plate solution (bar 21,Example 4) that constitutes about 54% of the weight of the innerstructure fully composed of PP-LGF with no laminate reinforcements (bar18, Example 1).

FIGS. 8 and 9 show embodiments of the hybrid tailgate inner structurecomprising an inner cover 16, 17 to cover the inner structure. FIG. 8shows a first embodiment of the inner cover 16, where the inner cover 16covers the area enclosed by the further reinforcement parts 12,excluding these further reinforcement parts 12. Such a smaller innercover 16 can be used when the aesthetic appearance of the furtherreinforcement parts is sufficient to act as the aesthetical surface inthe non-covered areas.

FIG. 9 shows a second embodiment of the inner cover 17, where the innercover 17 covers the area enclosed by the further reinforcement parts 12,including these further reinforcement parts 12. Such an extended innercover 17 is then used as the aesthetical cover for the furtherreinforcement parts 12.

The present invention discloses a composite hybrid tailgate innerstructure wherein continuous fiber composite and unfilled/filledthermoplastic composite are used in combination, to meet stringentmechanical requirement while providing weight reduction of the tailgateinner structure.

The continuous fibers in the composite can be glass, carbon, aramid orany other thermoplastic based fibers, or any combination thereof. Thelaminate used can be based on a unidirectional tape or on a fabric or acombination thereof. The fiber content in the laminate or tape can varyfrom 35% to 65% by volume.

The laminate used is obtained by stacking a number of plies (layers) oneover the other, either in the same orientation to get directionalproperties, or in multiple orientation to get quasi-isotropic propertiesfor the laminate. Laminates with different stacking sequences can beused in combination throughout the part to obtain the desiredproperties. The laminate can either be of constant thickness or have avariable thickness over its length.

The over-molding material is preferred to comprise short or long fiberfilled material. The filling fiber can be glass, carbon, aramid or anyother thermoplastic based fiber. The fiber filling content of theover-molding material and/or the PP-LGF material can vary from 10% to50% by weight.

Preferably, the matrix material in the continuous fiber laminate and theover-molding resin are compatible, more preferred even similar, toachieve good bonding between the laminate and the over-molding material.Alternatively, the laminate may be joined to the resin material parts bymeans of gluing or mechanical fastening.

The invention further relates to a method of manufacturing a hybridtailgate as described above. The current composite hybrid tailgate innerstructure may be manufactured using a process comprising placing thecomposite material laminate in an injection molding machine; forming thecomposite material laminate in a desired insert shape while closing theinjection molding tool; and over-molding the insert with polymer orthermoplastic resin.

Alternatively, or additionally, the method may comprise forming thelaminate shape in a pressing tool, for example a vertical press, forminga shaped insert; and positioning the shaped insert inside the injectionmolding tool. The insert may then be over-molded to fill the remainingcavities in the injection mold tool. The upstanding wall or wallsforming the ribbing may be manufactured during the over-molding step inthe process.

The insert can either be a 2D, i.e. flat, shape, or a 3D shape. Theinsert may comprise an open channel 24 with a channel base 30 andchannel upstanding walls 31. The ribbing structure or ribbing may beprovided in the channel 24 and extending from the channel base 30 andbetween the channel upstanding walls 31, on a similar side or onopposite sides of the base, see FIG. 5.

The invention also relates to a vehicle comprising such a hybridtailgate comprising an inner structure as described above.

1. A hybrid tailgate for a vehicle, comprising a thermoplastic innerstructure forming the carrier frame of the tailgate, and at least onecomposite reinforcement part to reinforce the carrier frame, wherein thecomposite reinforcement part is connected to the thermoplastic innerstructure at a first surface, wherein the composite reinforcement partforms a continuous load path in the inner structure enclosing a tailgatewindow opening for a window glazing part of the tailgate.
 2. The hybridtailgate according to claim 1, wherein the composite reinforcement partis connected to and forms an integral unit with the thermoplastic innerstructure at the first surface, wherein the composite reinforcement partcomprises a ribbing structure extending from the first surface, whichribbing structure forms a continuous load path in the inner structuresurrounding the tailgate window opening.
 3. The hybrid tailgateaccording to claim 1, further provided with a hinge connection portion,a gas strut connection portion, and/or a lock receiving portion, andwherein the continuous load path of the reinforcement part extends froma first end of the lock receiving portion to a second end of the lockreceiving portion, thereby extending over the hinge connection portionand the gas strut connection portion.
 4. The hybrid tailgate of claim 1,wherein the reinforcement part comprises a base and at least oneupstanding reinforcement wall extending from a second surface of thereinforcement part, wherein the upstanding wall forms a ribbing alongthe base.
 5. The hybrid tailgate of claim 1, wherein the reinforcementpart further comprises a composite material laminate, comprising atleast one layer of a composite UD tape having a thermoplastic matrixmaterial with continuous reinforcing fibers embedded in the matrixmaterial.
 6. The hybrid tailgate of claim 5, wherein the continuousfibers in each layer of the laminate are oriented in a differentdirection with respect to a longitudinal direction of the laminate. 7.The hybrid tailgate of claim 5, wherein the composite material laminateforms at least a portion of the base of the reinforcement part and/orwherein the upstanding wall forming the ribbing extends from the baseformed by either the tape or the laminate.
 8. The hybrid tailgate ofclaim 5, wherein the tailgate is free of metal reinforcement parts. 9.The hybrid tailgate of claim 1, comprising in combination a continuousfiber composite material and an unfilled or filled thermoplasticcomposite material.
 10. The hybrid tailgate according to claim 5,wherein the continuous fibers comprise at least one of glass fiber,carbon fiber, aramid fiber or a thermoplastic fiber.
 11. The hybridtailgate according to claim 1, wherein one or more reinforcement partsis located at critical load bearing locations of the carrier frame. 12.The hybrid tailgate according to claim 5, wherein the composite materiallaminate is provided at one or more of a D-pillar, a top beam and alower portion, and wherein the ribbing overlaps with the compositematerial laminate to form the continuous load path in the innerstructure.
 13. The hybrid tailgate according to claim 5, wherein thethermoplastic matrix material of the composite laminate is compatiblewith the thermoplastic material of the ribbing and/or the thermoplasticmaterial of the inner structure.
 14. A vehicle comprising the hybridtailgate according to claim
 1. 15. A method of manufacturing the hybridtailgate according to claim 6, comprising: forming a composite materiallaminate into an insert; placing the insert in an injection moldingtool; and over-molding the insert with polymer resin.
 16. The methodaccording to claim 15, wherein the composite material laminate is formedinto the insert by closing the injection molding tool, thereby forcingthe composite material laminate into a desired insert shape.
 17. Themethod according to claim 15, wherein the step of forming a compositelaminate part into an insert comprises placing the composite laminatepart in a pressing tool; and the method further comprises: positioningthe insert inside the injection molding tool; and over-molding theinsert by filling the injection molding tool.